Microwave fabrication of airfoil tips

ABSTRACT

A method of producing a metallic component includes: providing a body made of a first alloy; providing a preform comprising a metallic powder made of a second alloy and formed in the shape of an extension of the body; and heating the preform with microwave energy to sinter the metallic powder together and to bond the preform to the body. The method may be used to make new components as well as to repair or modify existing components.

BACKGROUND OF THE INVENTION

This invention relates generally to high-temperature components for gasturbine engines and more particularly to turbine airfoils.

Thermal and mechanical loads applied to the leading and trailing edgesand tips of a gas turbine engine airfoil can adversely affect theairfoil's useful life. Airfoils in gas turbine engines experiencedurability problems at the tip of the airfoil in the form of crackingdue to thermally induced stress and material loss due to oxidation andrubbing. This can be addressed by using an alloy having increasedresistance to environmental oxidation and corrosion. However, it isundesirable to upgrade the entire airfoil to a more thermal-resistantand oxidation-resistant alloy because this increases component cost andperhaps weight.

Materials having better high temperature properties than conventionalsuperalloys are available. However, their increased density and costrelative to conventional superalloys discourages their use for themanufacture of complete gas turbine components, so they are typicallyused as coatings or as small portions of components. These highlyenvironmentally resistant materials have proven difficult to attach tothe basic airfoil alloys due to a mismatch in liquidus and solidustemperatures between the environmentally resistant alloys (higherliquidus and solidus) and the component alloys (lower liquidus andsolidus). This mismatch is great enough that by the time the solidus ofthe environmentally resistant alloy is reached the liquidus temperatureof the component alloy is far exceeded resulting in a melt away of thecomponent. In processes to date that do join the blade alloy to the tipalloy a distinct centerline is formed in the joint. Experience predictsthat this type of joint is likely to fail in either fatigue or rupture.

Accordingly, there is a need for a method of attaching environmentallyresistant alloys to conventional superalloys.

BRIEF SUMMARY OF THE INVENTION

The above-mentioned need is met by the present invention, whichaccording to one aspect provides a method of producing a metalliccomponent, including: providing a body made of a first alloy; providinga preform including a metallic powder of a second alloy formed in theshape of an extension of the body; and heating the preform withmicrowave energy to sinter the metal powder together to bond the preformto the body.

According to another aspect of the invention, a method of producing anairfoil includes: providing an airfoil body made of a first alloy andhaving curved pressure and suction sides, a tip cap disposed between thepressure and suction sides at a radially outer end of the airfoil bodyand a partial height squealer tip extending radially outwards from thetip cap; providing a preform including a metallic powder of a secondalloy different from the first alloy and formed in the shape of anextension of the squealer tip; positioning the preform on the squealertip; and heating the preform with microwave energy to sinter the metalpowder together in a consolidated squealer tip extension, and to bondthe squealer tip extension to the body.

According to another aspect of the invention, a method of modifying anairfoil includes: providing an airfoil body made of a first alloy andhaving curved pressure and suction sides, a tip cap disposed between thepressure and suction sides at a radially outer end of the airfoil body,and a squealer tip extending radially outwards from the tip cap;removing a portion of the squealer tip so as to reduce its height in aradial direction; providing a preform comprising a metallic powder of asecond alloy different from the first alloy and formed in the shape ofan extension of the squealer tip; disposing the preform on the squealertip; and heating the preform with microwave energy to sinter themetallic powder together in a consolidated squealer tip extension, andto bond the squealer tip extension to the body.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be best understood by reference to the followingdescription taken in conjunction with the accompanying drawing figuresin which:

FIG. 1 is a perspective view of an exemplary prior art turbine blade;

FIG. 2 is a cross-sectional view of a portion of the turbine blade ofFIG. 1, showing a squealer tip thereof;

FIG. 3 is a perspective view of a preform for a squealer tip;

FIG. 4 is a schematic cross-sectional view of a preform inside amicrowave chamber; and

FIG. 5 is a schematic side view of an alternative process for attachinga squealer tip preform to an airfoil.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings wherein identical reference numerals denotethe same elements throughout the various views, FIG. 1 depicts anexemplary turbine blade 10 for a gas turbine engine. The presentinvention is equally applicable to the construction of other types ofmetallic components, such as stationary turbine vanes, frames,combustors, and the like. The turbine blade 10 comprises an airfoil 12having a leading edge 14, a trailing edge 16, a tip 18, a platform 20, aconvex suction sidewall 22, and a concave pressure sidewall 24. Anarcuate inner platform 26 is attached to the platform 20 of the airfoil12.

In manufacturing the airfoil 12, the pressure and suction sidewalls 24and 22, a tip cap 28, and a partial height squealer tip 30 areintegrally cast as a one-piece airfoil body 32. The airfoil body 32 istypically cast from known type of a nickel- or cobalt-based superalloyhaving high-temperature strength properties suitable for the intendedoperating conditions. Examples of known materials for constructing theairfoil body 32 include RENE 77, RENE 80, RENE 142, and RENE N4 and N5nickel-based alloys.

A squealer tip extension 34 is bonded to the partial height squealer tip30. The squealer tip extension 34 preferably comprises an alloy whichexhibits superior high-temperature oxidation resistance compared to thebase alloy of the airfoil body 32.

One example of a suitable material for this purpose is a rhodium-basedalloy comprising from about three atomic percent to about nine atomicpercent of at least one precipitation-strengthening metal selected fromthe group consisting of zirconium, niobium, tantalum, titanium, hafnium,and mixtures thereof; up to about four atomic percent of at least onesolution-strengthening metal selected from the group consisting ofmolybdenum, tungsten, rhenium, and mixtures thereof; from about oneatomic percent to about five atomic percent ruthenium; up to about tenatomic percent platinum; up to about ten atomic percent palladium; andthe balance rhodium; the alloy further comprising a face-centered-cubicphase and an L1₂-structured phase.

Another suitable material for the squealer tip extension 34 is a secondrhodium-based alloy comprising rhodium, platinum, and palladium, whereinthe alloy comprises a microstructure that is essentially free ofL1₂-structured phase at a temperature greater than about 1000° C. Moreparticularly, the Pd is present in an amount ranging from about 1 atomicpercent to about 41 atomic percent; the Pt is present in an amount thatis dependent upon the amount of palladium, such that: a) for the amountof palladium ranging from about 1 atomic percent to about 14 atomicpercent, the platinum is present up to about an amount defined by theformula (40+X) atomic percent, wherein X is the amount in atomic percentof the palladium; b) for the amount of palladium ranging from about 15atomic percent up to about 41 atomic percent, the platinum is present inan amount up to about 54 atomic percent; and the balance comprisesrhodium, wherein the rhodium is present in an amount of at least 24atomic percent.

Unfortunately the mismatch between the melting points of the squealertip extension 34 and the airfoil body 32 is great enough that by thetime the solidus of the environmentally resistant alloy is reached theliquidus temperature of the airfoil body alloy is far exceeded resultingin a melt away of the airfoil body 32.

FIG. 3 depicts a preform 36 for a squealer tip extension for use withthe present invention. The preform 36 substantially matches theperipheral shape of the partial height squealer tip 30, and has a radialheight “H”. The radial height H is selected to provide adequateprotection for the airfoil body 32 from high-temperature oxidation,while minimizing the amount of material used. The radial height “H” maybe a thin, foil-like dimension of about 0.127 mm (0.005 in.), or it maya more substantial thickness. In the illustrated example the radialheight “H” is about 1.27 mm (0.050 in.)

The preform 36 may be constructed in various ways. For example, it maybe prepared by a known powder metallurgy (PM) process in which ametallic powder is mixed with a lubricant and pressed into a die underhigh pressure. Alternatively, the preform 36 may be constructed througha metal injection molding (MIM) process in which a fine metallic powderis mixed with a plastic binder and extruded to a desired shape usingplastic molding equipment. The resulting preform is chemically washed toremove a large portion of the plastic from the powder before subsequentsintering. Regardless of the process used to make the preform, theparticle size of the metallic powder should be less than about 100micrometers in diameter, to ensure compatibility with the microwavesintering process described below.

The process of attaching the preform 36 to the airfoil body 32 isdepicted in FIG. 4. The preform 36 is placed on top of the partialheight squealer tip 30. If necessary, a fixture may be used totemporarily retain the preform 36 in place. The airfoil body 32 is thenplaced in a chamber 38 which includes means for creating a suitableatmosphere to prevent undesired oxidation of the preform 36 or otherreactions during the attachment process. In the illustrated example asupply 40 of inert gas such as argon is connected to the interior of thechamber 38. A microwave source 42 such as a known type of cavitymagnetron with an output in the microwave frequency range is mounted incommunication with the chamber 38. The microwave spectrum covers a rangeof about 1 GHz to 300 GHz. Within this spectrum, an output frequency ofabout 2.4 GHz is known to couple with and heat metallic particleswithout passing through solid metals.

The microwave source 42 is activated to irradiate the preform 48. In theillustrated example the microwave source 42 is depicted as having adirect line-of-sight to the entire preform 36. However, it is alsopossible to configure the chamber 38, which would typically be metallic,so that the preform 36 is heated by a combination of direct andreflected microwaves. Because of the small metallic particle size in thepreform 36, the microwaves couple with the particles and heat them. Thepreform 36 is heated to a temperature below the liquidus temperature ofthe metallic powder and high enough to cause the metallic powderparticles to fuse together and consolidate. The high temperature alsomelts and drives out any remaining binder. Since the microwave energywill not couple with the bulk material of the airfoil body 32, heatingof the airfoil body 32 will occur solely through conduction through thepreform 36. This will produce enough heat during the sintering processto cause the airfoil body 32 to braze itself to the preform 36 by way ofcapillary action.

The preform 36 is held at the desired temperature for a selected timeperiod long enough to result in a consolidated squealer tip extension34, and to bond the squealer tip extension 34 securely to the airfoilbody 32. The heating rate (i.e. the output wattage of the microwavesource) is selected depending on variables such as the mass of thepreform 36, the shape of the chamber 38 and the and the desired cycletime of the sintering process.

When the sintering cycle is complete, the turbine blade 10 is removedfrom the chamber 38 and allowed to cool. If desired, the turbine blade10 may be subjected to additional processes such as final machining,coating, inspection, etc. in a known manner.

FIG. 5 illustrates an alternative method of creating a preform 36′. Amold or dam 43 is formed around the radially outer end of the airfoilbody 32. A core 44 may be inserted into the dam 43 to define an innerperimeter. A preform 36′ is then created through a metal injectionmolding (MIM) process using the extruding apparatus 46 shown. After thepreform 36′ is constructed in place, it is microwave sintered asdescribed above to consolidate it and bond it to the airfoil body 32. Ifthe dam 43 is constructed from a microwave-transparent material, thenthe preform 36′ may be sintered without removing the dam 43.

Regardless of how the preform 36 is constructed, the airfoil body 32 andsquealer tip extension 34 may be subjected to further consolidationusing a known hot isostatic pressing (“HIP”) process to ensure that thesquealer tip extension is substantially 100% dense.

It should be noted that the above-described method of attachment of asquealer tip extension is equally applicable both to new make and torepair or modification of existing components. For example, a turbineairfoil having a conventional squealer tip extension 34 may be repairedor upgraded by removing the squealer tip extension, and then attaching anew squealer tip extension as described above.

The foregoing has described an airfoil tip manufacture or repairprocess. While specific embodiments of the present invention have beendescribed, it will be apparent to those skilled in the art that variousmodifications thereto can be made without departing from the spirit andscope of the invention. Accordingly, the foregoing description of thepreferred embodiment of the invention and the best mode for practicingthe invention are provided for the purpose of illustration only and notfor the purpose of limitation, the invention being defined by theclaims.

1. A method of producing a metallic component, comprising: providing abody made of a first alloy; providing a preform comprising a metallicpowder made of a second alloy and formed in the shape of an extension ofsaid body; heating said preform with microwave energy to sinter saidmetallic powder together and to bond said preform to said body.
 2. Themethod of claim 1 wherein said preform is fabricated by: providing amixture of a metallic powder of a second alloy and a binder; meltingsaid binder and casting said mixture in a mold to form a preform; andleaching said preform to remove excess binder.
 3. The method of claim 1wherein a majority of said binder is removed by washing said preformwith a solvent selected to dissolve said binder but not said metallicpowder.
 4. The method of claim 1 wherein said preform is fabricated by:providing a metallic powder of a second alloy; and compacting saidmetallic powder into a mold under pressure to form a preform.
 5. Themethod of claim 1 wherein said microwave heating is carried out with acavity magnetron.
 6. The method of claim 1 wherein said preform and saidbody are disposed in a chamber provided with a controlled compositionatmosphere during said heating.
 7. The method of claim 7 wherein saidatmosphere is an inert gas.
 8. The method of claim 1 wherein saidmetallic powder comprises a rhodium-based alloy.
 9. The method of claim1 wherein said preform is fabricated within a dam disposed around aradially outer end of said body.
 10. A method of producing an airfoil,comprising: providing an airfoil body made of a first alloy and havingcurved pressure and suction sides, a tip cap disposed between saidpressure and suction sides at a radially outer end of said airfoil bodyand a partial height squealer tip extending radially outwards from saidtip cap; providing a preform comprising a metallic powder of a secondalloy different from said first alloy and formed in the shape of anextension of said squealer tip; positioning said preform on saidsquealer tip; and heating said preform with microwave energy to sintersaid metal powder together in a consolidated squealer tip extension, andto bond said squealer tip extension to said body.
 11. The method ofclaim 10 wherein said preform is fabricated by: providing a mixture of ametallic powder of a second alloy and a binder; melting said binder andcasting said mixture in a mold to form a preform; and leaching saidpreform to remove excess binder.
 12. The method of claim 10 wherein amajority of said binder is removed by washing said preform with asolvent selected to dissolve said binder but not said metallic powder.13. The method of claim 10 wherein said preform is fabricated by:providing a metallic powder of a second alloy; and compacting saidmetallic powder into a mold under pressure to form a preform.
 14. Themethod of claim 10 wherein said microwave heating is carried out with acavity magnetron.
 15. The method of claim 10 wherein said preform andsaid body are disposed in a chamber provided with a controlledcomposition atmosphere during said heating.
 16. The method of claim 1 5wherein said atmosphere is an inert gas.
 17. The method of claim 10wherein said metallic powder comprises a rhodium-based alloy.
 18. Themethod of claim 10 wherein said preform is fabricated within a damdisposed around a radially outer end of said body.
 19. A method ofmodifying an airfoil, comprising: providing an airfoil body made of afirst alloy and having curved pressure and suction sides, a tip capdisposed between said pressure and suction sides at a radially outer endof said airfoil body, and a squealer tip extending radially outwardsfrom said tip cap; removing a portion of said squealer tip so as toreduce its height in a radial direction; providing a preform comprisinga metallic powder of a second alloy different from said first alloy andformed in the shape of an extension of said squealer tip; disposing saidpreform on said squealer tip; and heating said preform with microwaveenergy to sinter said metallic powder together in a consolidatedsquealer tip extension, and to bond said squealer tip extension to saidbody.
 20. The method of claim 19 wherein said preform is fabricated by:providing a mixture of a metallic powder of a second alloy and a binder;melting said binder and casting said mixture in a mold to form apreform; and leaching said preform to remove excess binder.
 21. Themethod of claim 19 wherein a majority of said binder is removed bywashing said preform with a solvent selected to dissolve said binder butnot said metallic powder.
 22. The method of claim 19 wherein saidpreform is fabricated by: providing a metallic powder of a second alloy;and compacting said metallic powder into a mold under pressure to form apreform.
 23. The method of claim 19 wherein said microwave heating iscarried out with a cavity magnetron.
 24. The method of claim 19 whereinsaid preform and said body are disposed in a chamber provided with acontrolled composition atmosphere during said heating.
 25. The method ofclaim 24 wherein said atmosphere is an inert gas.
 26. The method ofclaim 19 wherein said metallic powder comprises a rhodium-based alloy.27. The method of claim 19 wherein said preform is fabricated within adam disposed around a radially outer end of said body.